eden psu csat 2011.update
TRANSCRIPT
ARLPenn State
Navy ManTech Cold Spray Programs The Institute for Manufacturing and
Sustainment Technologies
Timothy Eden, [email protected]
A Navy Manufacturing Technology Center of Excellence
ARLPenn State Background / Core Competencies
• U.S. Navy established the Applied Research Laboratory at Penn State in 1945
• In 1996, DoD reaffirmed its strategic relationship and commitment by designating ARL as a University Affiliated Research Center (UARC)
• Trusted agent for the DoD• Train next generation of Engineers
• ARL is primarily a science and technology based laboratory with leadership in the following core competencies:
• Materials and Manufacturing• Acoustics• Guidance and control• Thermal energy systems• Hydrodynamics, hydroacoustics, and
propulsor design • Navigation and GPS• Communications and information• Graduate educationJOINT STRIKE FIGHTER
AAAV
VEHICLE FIELD EXERCISE
ARLPenn State
• The Navy ManTech Program develops and implements enabling manufacturing technology in the form of new equipment and processes– Supplements industry’s ability to support DoD
acquisition, weight reduction or Life Cycle Cost reduction efforts
– Funded by ONR and associated stakeholders (program offices, directly related OEM’s)
– Leverage funding to support larger programs– Funding may include subcontracts to industry,
government or other ManTech COE’s– Requirements
– Approval from Stakeholder– Clear Transition Path– One to three years duration
Manufacturing Technology Program
ARLPenn State iMAST Overview
• iMAST established February 1995 • Address advanced weapon system issues• Development & transition of new
manufacturing processes & equipment supporting Navy acquisition and sustainment programs
• Projects contribute to affordability, life cycle cost reduction and sustainment
• Repair Technology (REPTECH) Projects: Repair, overhaul and sustainment
• Target fielded weapon systems and provide the process and equipment technology needed to repair and maintain fleet assets
• Implementation at naval depots, shipyards, Marine Corps logistics bases, intermediate maintenance activities and contractor facilities
ARLPenn State
• Presentation Outline• Portable Cold Spray Repair and Restoration• Corrosion Resistant Coatings for Magnesium Transmission
Gearboxes for SH60• AAV Enhanced Appliqué Armor Kit Product Improvement
Introduction
ARLPenn State Portable Cold Spray Repair
Objective: •Develop portable processes for repair and restoration of Aluminum and Magnesium Components
Approach:•Survey available portable Cold Spray Systems
• Perform test to evaluate Cold Spray Systems• Select Cold Spray System – Compliment NAVAIR
• Cherry Point – CGT Portable•NAVAIR components
• AMAD Transmission Housing Cover• IVD Aluminum Repair• AH-1 and UH-1N Support Case Mount Foot• H-60 Tail Cone Bulkhead
•Develop process to repair components•Perform qualification testing•Develop implementation requirements (safety, personal protection, etc.)
•Transition technology
ARLPenn State Portable Cold Spray Repair
• Develop Cold Spray Repair – Transmission Housing• Dimensional restoration• High adhesion strength• Hardness comparable to A357 • Good Machinability• Rapid Response
• Approach• Process Development• Repair Validation• Repair Housing
• Compare Results to HP Systems A357.0-T61Hardness of 113 VHN (41 Rockwell A) Ultimate Tensile= >45ksi Tensile = >36ksiCompositionAl-7%SiTi = 0.04-0.20%
ARLPenn State Portable Cold Spray Repair
Damaged areas
ARLPenn State Portable Cold Spray Repair
Initial Set-up• Type of repair
• Dimensional• Structural
• Powder Selection • Material Compatibility • Hardness• CTE Match• Size and morphology
• Surface Preparation• Material removal• Bead blasting• Surface roughness
• Cold Spray System• Process parameters
• Modeling – initial parameters• Process Gas – Type, Pressure, Temperature• Nozzle• Traverse rate
• Powder testing• Size Distribution• Morphology
SEM of Al-12Si
ARLPenn State Portable Cold Spray Repair
• Powders• CP-Al, AA6061 and AA4047
• Systems• High Pressure
• CGT 4000/47 with He, N2• Ktech He, N2
• Low Pressure• Centerline SST with He, N2 and Compressed Air
• Surface Prep – Glass Bead (G3) Media Blasting• Microstructure Results AA4047
• Porosity <0.1%•Galvanic Corrosion AA4047
CGT (He) - 100x CGT (N2) - 100x
SST (He) - 100x
Al 12-Si – A357
CGT (N2) - 100x
ARLPenn State
Initial System Repair Results
CGT-HP N2 106 12.1*CGT-HP He 117-137 8.5-11.2*CGT- Portable HESST - Portable HE 141 6* glue failures
SystemHardness (VHN)
Bond Strength (ksi)
Main Process Gas
Initial System Comparison Results
ARLPenn State
Initial System Repair Results
A357 Casting – Al-12 Si repair with Centreline Portable System
ARLPenn State
Initial System Repair Results
A357 Casting – Al-12 Si repair with Centreline Portable System
ARLPenn State
Initial System Repair Results
A357 Casting – Al-12 Si repair with Centreline Portable System
ARLPenn State Cold Spray Repair HP System
Repair• Surface Preparation• Masking• Coating Application• Final Machining• Dimensional Measurements• Visual Inspection• Acceptance Testing
•Requirements/Specification•NDE •Thermal Cycling
• Technology Transfer• Documentation
Repaired Housing
Damaged Housing
ARLPenn State Cold Spray Transition
Transition Locations• US Naval Aviation Depot, Cherry Point, NC (FRC-E) • North Island, CA (FRC-SW)• Jacksonville, FL (FRC-SE)
• Program will be completed in 18 months
ARLPenn State
Cold Spray Aluminum for the Corrosion Protection of Mg Gearbox:Aluminum-Magnesium Galvanic Corrosion
Project Objective• Apply a corrosion resistant barrier coating of Al to Mg using Cold
Spray
• Leverage Project with ESTCP Supersonic Particle Deposition Technology for Repair of Magnesium Aircraft Components
• Powder Development and Evaluation
• Corrosion Testing
• Supporting Transition
ARLPenn State SH-60 Gearbox Repair
Magnesium highly susceptible to galvanic corrosion• Most electrochemically negative structural metal
• Thermodynamic driving force to corrode when coupled to any metal
Galvanic corrosion possible on Al-coated gearbox• Edge of coating (Al-Mg interface)
• Scratched/damaged coating (Mg exposed)
Powder Development and Evaluation• Commercially Pure Al (CP) (99.5% Al)
• High Purity (HP) Al (99.95% Al)
• High Purity (HP) Al-5 wt.% Mg (95% Al) – Produced at PSU
• Al 5356 (5 wt.% Mg)
• Al 4047 (12 wt.% Si)
• Al 6061
ARLPenn State
Particle Characterization
Particle Size Distribution - Al Powders
0
2
4
6
8
10
12
14
1 10 100 1000
Particle Diameter (microns)
Volu
me
Perc
ent
CP Al (Al 101)
5356 Al
CP Al (13/325)
HP Al (9-40 HP)
CP Al (H-12)
4047 Al
HP Al (-20)
CP Al (H-5)
CP Al - 18 µm
HP Al - 23 µm4047 Al - 13 µm CP Al - 42 µm
SH-60 Gearbox Repair
ARLPenn State
0
20
40
60
80
100
120
140
160
Wrought Al HP Al N2 HP Al He HP Al He HT
HP Al5Mg He
HP Al5Mg N2
HP Al5Mg N2 HT
CP Al (42 µm)
CP Al (18 µm)
4047 Al 5356 Al Substrate (Mg)
Har
dnes
s (V
icke
rs 1
00g)
Cold Spray Coating
Hardness of Aluminum Powders applied by Cold Spray
SH-60 Gearbox Repair
ARLPenn State
Experimental:• Mg and Al-coated Mg coupons electrically coupled by ZRA in 3.5% NaCl
• Current measured
Galvanic Couple – ASTM G71
Results:• HP Al yielded no galvanic
current (similar to Mg-Mg couple)
• Al-5Mg shows higher current due to contamination from crucible
0.01
0.1
1
10
None (Bare Mg)
HP Al Al-5Mg He
Al-5Mg N2
5356 4047 CP Al
Cur
rent
(A/c
m2)
Coating Material
Galvanic Corrosion - Al-Mg Couple
Coating Mean Std Dev 95% CINone (Bare Mg) 0.046 0.03 0.00, 0.09HP Al 0.029 0.01 0.00, 0.04Al-5Mg He 0.155 0.04 .11, .20Al-5Mg N2 0.473 0.06 .37, .575356 2.03 0.34 1.61, 2.464047 2.24 0.14 1.89, 2.58CP Al 2.33 0.38 1.86, 2.81
ARLPenn State
Experimental• Mg panel coated with Al on both faces with Mg edges uncoated (sandwich)
• Weight loss determined (2 samples per condition)
Results• HP Al coated panel showed little material loss
• CP Al subject to enhanced galvanic corrosion and cathodic corrosion
Galvanic Couple – Salt Spray
0
10
20
30
40
50
60
7 15 28
% W
eigh
t Los
s
Salt Spray Exposure Time (days)
HP
HP Al5Mg
CP
ARLPenn State
Corrosion Testing – Galvanic Couple (ASTM B-117)• HP Al showed little material loss
• CP Al subject to enhanced galvanic corrosion and cathodic corrosion
Comparison galvanic coupling of high purity and commercially pure Cold Spray aluminum coatings with ZE41A-T5 Mg
panel (0.25” thick) after two weeks in salt spray chamber (ASTM B117). Coating
applied to front and back of Mg (Edges of Mg exposed). Left – high purity Al. Right
– commercially pure Al.
Galvanic Couple – Salt Spray
HP Al
HP Al CP Al
CP Al
ARLPenn State
• Summary• Leveraged ESTCP Program• Performed Corrosion and Materials Evaluation• Developed Powders for improved corrosion• Provided input for selection of powders with optimal
combination of properties
SH-60 Gearbox Repair
ARLPenn State AAV Problem Statement
• Appliqué Armor was corroding at a very high rate• Damage to CARC Paint
• Handling – installation and removal• Shipping• Storage• Operation
• Maintenance Procedures• Cadmium coatings on bolts and washers were an
environmental hazard
ARLPenn State
• Visit Camp LeJeune to understand installation, removal, operating conditions, and storage
• Indentified corrosion mechanisms and initiation path• Evaluated steel, rubber, binder and CARC coating• Evaluated CP Al, Zn and Zn-Al coatings• Coatings applied with Cold Spray and thermal spray and
sealed with mil spec paint.• Preformed alternate Immersion tests at ARL and at LaQue
Corrosion Technology Center, environmental exposure, impact testing, galvanic testing
• Evaluated alternatives to cadmium plated bolts• Coated four full sets of armor• Field tested on two long term deployments• Cost analysis
AAV Program Overview
Mild SteelRubberHardened Steel
ARLPenn State Cold Spray Coated Panels
6669266 – APK Slope
6669255-C - APK Step
Alternate Immersion TestingTop- With CP-Al
Bottom – Uncoated
ARLPenn State Deployment Results - Cold Spray
B212: Step - Cold Spray CP-Al Inside and outside
B205: Step -Thermal Spray CP-Al Inside and outside
B201: Thermal Spray CP- Al InsideZn Primer outside
ARLPenn State
B205: Slope – Cold Spray CP-Al inside and outside CARC damaged - Armor still protected
Deployment Results - Cold Spray
ARLPenn State Deployment Results - Fasteners
Cadmium Plated Bolts
Bolts with Al/Zn Plating (Dacromet 320)
Cadmium and Dacromet 320 have similar performance –Dacromet 320 does not have the environmental hazard
ARLPenn State Deployment Summary
Field Test Coating Matrix
Armor Set EAAK 1 EAAK 2 EAAK 3 EAAK 4
Slope Inside TS CP-Al TA CP-Al CS CP-Al CS CP-Al
Slope Outside TS CP-Al TA CP-Al CS CP-Al CS CP-Al
Step Inside TS CP-Al TA CP-Al CS CP-Al CS CP-Al
Step Outside Zn – primer TA CP-Al Zn - primer CS CP-Al
Edge Polysulfide Polysulfide Polysulfide Polysulfide
Valley Bolts Al/Zn Al/Zn Al/Zn Al/Zn
Typical Deployment Activities April to OctSwim to transport shipSwim to shore/return – training exercises12 ship to shore-operationsFour different European locations
ARLPenn State
Damage Mitigation• Panels coated with CP-Al performed better than panels
with a thick zinc primer during deployment• Panels coated with CP-Al using Cold Spray performed
better than panels coated using thermal spray• Edges damaged during installation and removal
• Edge sealants protect edges• Damage during shipping and handling
• Al coating and sealant improves corrosion resistance• Impact during use
• Al coating and sealant improves corrosion resistance• Application of CARC with large silicon carbide particles
• Change application procedure and SiC particle size• Cadmium plating is an environmental and health hazard• Al/Zn (Dacromet 320) greatly reduced environmental and
health hazards• Cold Spray cost competitive with wire-arc thermal spray• Developed Cost Software – verified coating large panels
Deployment Results
ARLPenn State
iMAST/Navy ManTech• Bridge the technology transition valley of death
• Clear transition path
• Can be used to support existing program
• Excellent technology transfer/ implementation
• Can work with OEMs, government, and equipment manufacturers
Acknowledgements
Work sponsored by United States Navy Manufacturing Technology (ManTech) Program, Office of Naval Research,
Summary